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Web 101.

72SM How to Move

Roller Alignment - Mechanics

Figure Courtesy of Oasis Alignment Services

2012 David Roisum, Ph.D. Finishing Technologies, Inc.

72.1

Why is Alignment So Important?


Affects the Web: Flatness: Bagginess and apparent Bagginess Position: Path and Registration (e.g. Printing) Runnability (Web Breaks) Winding: Roll Quality Wrinkles

72.2

Two Views of Alignment


Mechanical
Level Square Common Centerlines

Web Handling
In-plane (bending)
Path control Web breaks Wrinkles

Out-of-plane (twisting)
Web damage/breaks at edges Center wrinkle

Offset Centerlines
Guide runs off center Web runs off center
72.3

Hand Tools - Types

Pi Tape

Figures Courtesy of Oasis Alignment Services 72.4

Hand Tool - Limitations


Level
At best good to 0.001/foot (Optics can be 20X tighter)

Square
There is no squaring tool Parallelism Problems
1

Doesnt help square vertical spans (1-2 and 3-4) Accumulation of error

Level and Square


Large Tendency to Sloppiness
72.5

Hand Tool Application


Step 1 I might have Step 2 Verify working hypothesis that problem an alignment related might be exacerbated by problem misalignment Path Control
Printer Registration Wound Roll Edge

Level by level Parallel by Pi Tape

Web Breaks Step 3 Align (Optics?) (Diagonal) Wrinkling

72.6

Optical Tooling

Similar to surveying equipment, but > 10X more precise


Figures Courtesy of Oasis Alignment Services 72.7

Baseline Installation
Alignment means
Establishing offset centerline for alignments Look for monuments (small plugs) in floor

Figure Courtesy of Oasis Alignment Services 72.8

Centerline Survey
Alignment means
Level, Square, AND Middle of Rollers on Same Centerline

Figure Courtesy of Oasis Alignment Services 72.9

Squaring With Optics


Precision Square w.r.t. Baseline
Uses a pair of TTS Precision right angles

Figure Courtesy of Oasis Alignment Services 72.10

Other High Tech Alignment Tools

Laser Trackers Laser Shaft Alignment The standard for motor to roller alignment Gyroscope

Coordinate Measuring Total Station

Gyro Fast setup and position readout

Figures Courtesy of Oasis Alignment Services 72.11

Alignment Details - Preparation


$$$ for Downtime Machine Builder
Standards & Instructions Alignability

Design for Service (alignability)


Individual rollers easily moved Preserve Level
Shear ledge Jack bolts

Maintenance
Remove Excess Rollers Roller Maintenance Dowel/Mark

Dowel Pin

Align Crew

Shear Ledge

Plug Lines Report with before & after readings

Match Drilled Frames?

Dunn, Jim M. Precision Alignment of Winders. Tappi J., vol 79, no 6, pp 67-71, June 1996 Williams, Fritz (OASIS). Alignment Methods and Best Practices for Cost Effective Alignment 72.12 of Production Equipment. AIMCAL AWEB, Charlotte, May 7-10, 2006

Alignment Challenges
Bearing Housings
At an angle Bolt bound designs (e.g., match drilled frames) No shear ledge

Alignment
No line of sight Flimsy floors Hand tools

Procedural
Lack of guidance
Which rollers How close

Rollers - General
Flimsy frames Flimsy foundations Loose mounting

Not enough time

Rollers Specific
Pivoting / translating Skewable Curved axis (bowed spreaders) Segmented

Special
Foil Close packed rollers Narrow rollers (wheels)
72.13

Review Questions
Why might we need to align? What are the instrument based definitions of alignment? What are the common measures of misalignment? What are the common realignment instruments?
72.14

Review Answers
Why might we need to align?
Path, web breaks, wrinkling

What are the instrument based definitions of alignment?


Level, square, common centerlines

What are the common measures of misalignment?


Precision level, Pi tape or trammel

What are the common realignment instruments?


Precision level, TTL
72.15

Questions?

Answers: David Roisum, Ph.D.


http://www.webhandlingblog.com/ http://www.roisum.com drroisum@aol.com 920-725-7671 office 920-312-8466 cell
72.16